2003 Chevrolet Malibu Logo
Posted on Jan 28, 2009
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Adjusting headlights Is there a special tool needed to adjust the headlights on a 2003 Chevy Malibu or is a screwdriver sufficient?

  • dbarbara74 Jan 31, 2009

    Thanks for advising me the name of the tool.

  • Anonymous Mar 20, 2014

    How to change water pump and is there any special tools

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1 Answer

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  • Posted on Jan 28, 2009
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Joined: Jan 27, 2009
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Their is a trox bit that you can pick up at your local hardware store. They should be able to get the right size.

Good luck.

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I have a 2001 chevy malibu which had to replace front bumper and now i need to adjust the headlights. On my brights tye left headlight shines upward really high and the right one shines to the left not as...

There are 2 screws on EACH headlight. One Screw does UP and DOWN and the other does LEFT/RIGHT.

These are normally an E Socket to adjust on a Chevy. there are some models taht use a Phillips Screwdriver Head to do the adjustments
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Headlight adjustment requires specialized tools.
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ADJUSTING HEADLIGHTS ON A 2000 CHEVY MALIBU WHAT IS THE PROPER PROCEDURE

All headlights have an adjuster, check youtube and it will show you the way.
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How to replace the headlight on a 1987 chevy el camino

Check this GM Chevy Mid-Size Cars 1964-1988 procedure from Repair Guide...


Headlights - REMOVAL & INSTALLATION
If some or all of the headlight bulbs being replaced still operate, refer to the headlight aiming procedure later in this section to ease checking or adjustment of the headlights after installation.
  1. Disconnect the negative battery cable.
  2. Loosen and remove the retaining screws, then remove the headlight bezel from the front of the vehicle.
  3. On most models, the headlight bulb retaining ring is only held on by retaining screws. If so, remove the bulb retaining ring screws. These are the screws which hold the thin metal ring which holds the bulb against the adjusting plate. Do not touch the two headlight aiming screws, at the center of the top and side of the retaining ring (these screws will have different heads), or the headlight aim will have to be re-adjusted.

One way to identify the retaining ring screws is that they will be threaded through a lip on the outer edge of the retaining ring before threading through the adjusting plate. One the other hand, the adjustment screws are threaded through the adjustment plate and a spring loaded holder underneath it.

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Fig. 1: Exploded view of a common dual headlight mounting assembly-1983 Malibu shown typical
  1. Some later model vehicles will use a spring on the retaining ring. If so equipped, disengage the spring from the retaining ring, using a cotter pin removal tool, then remove the retaining ring screws.
  2. Pull the bulb and ring forward and then separate them. Unplug the electrical connector from the rear of the bulb and remove the bulb from the vehicle.
To install:
  1. Plug the new bulb into the electrical connector.
  2. Position the retaining ring over the bulb, then install the assembly to the adjusting plate. Secure using the retaining screws and, if applicable, the spring.
  3. Install and secure the headlight bezel.
  4. Connect the negative battery cable.
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Loosen and remove the headlight bezel retaining screws

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Make sure all of the screws are removed, then pull the bezel from the front of the vehicle

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Loosen and remove the retaining ring screws

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Pull the retaining ring and bulb forward to separate them


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Unplug the electrical connector from the rear of the headlight


Hope helps (remember rated this).
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I am trying to change a headlight. I can't can not

The headlight assembly (1993 Grand Caravan) is held in place with three plastic "wing nuts" that rotate on the ball-end (front end) of the adjusting screws. One "adjusting screw" (the one on the bottom, inboard side) is not for adjusting, just for mounting. The other two adjusting screws take a torx T15 in the front end of the screw.
Removing the headlight assembly is somewhat of a trick - it seems like it takes a special tool to reach the "wing nut" and turm it 1/4 turn (90 degrees) CLOCKWISE (so the "wings" are vertical). When all three of these mounting "wing nuts" have the wings vertical, the headlight assembly just pulls forward and off these mounting nuts. Place the new assembly back over the "nuts", turn the 3 "wing nuts" another quarter turn, and the new unit is mounted. Probably not even a need to re-adjust the headlights, but you should check.
The PROBLEM, is that it appears to take a special tool to reach and turn these wing nuts without breaking them (yes, the old ones get brittle). I tried a socket (did not work), and then long needle-nose pliers (broke one wing nut), then a 1/2" open-end wrench (which at least worked). However, pushing the new assembly back over the wing nuts, I broke another wing nut. So, I broke 2 of the 6, and one was broken when I started.
Now I need to find replacements for these "wing nuts" ... any ideas where to get them?
Of course I can use some washers, some nuts to fit the fine-threaded adjustment screw, and some sort of bushing (maybe cut a short piece of rubber tubing to fit over the adjustment screw). Place double nuts (second nut to lock the first in place) and a washer, then the bushing onto the adjusting screw, then the headlamp assembly onto the bushing, then add another washer, and two more nuts (not too tight) to lock it onto the adjusting screw (which must still be free to rotate). Repeat for each of the 6 mounting points. I have not tried this yet, but ... it should work.

Fabricate a tool to turn the "wing nuts" using a piece of 3/8 inch ID tubing which you file or cut 1/8 inch by 1/8 inch notches on each side of a diameter line.
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Further to Emmisionwiz's answer that worked for me - the holes are in the black plastic covering the radiator support, to each side more or less in line with the headlights. They are marked with an "A" and rotation directions for UP and DOWN. The Phillips screwdriver goes into the hole about 45 degrees from vertical and engages the adjusting rack, where the teeth of the Phillips screwdriver are the pinion. If you shine a flashlight down the hole you can see the rack teeth and all becomes clear. But you will need a long Phillips screwdriver and a little bit of luck.

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the screws for adjusting the headights are right next to the lights, they are phillips heads and are for adjusting the side to side, 
the adjusting screws for the up and down, are on the bottom of the headlights, and they are a small hole in the grill trim, these lights need a pretty long skinny screwdriver with a phillips head
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